Integrated electric drive system and electric vehicle

Abstract

An integrated electric drive system comprising a motor, a reduction gear, a controller, and a one-piece housing, wherein a first housing space having a first opening and configured for mounting the controller is recessed into the one-piece housing; a second housing space configured for mounting the motor and a third housing space configured for mounting the reduction gear are arranged in a direction of the one-piece housing away from the first opening; the controller is connected to the motor; an output shaft of the motor is connected to the reduction gear; the second housing space is located below the first opening and the third housing space is located below the first opening.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to Chinese Patent Application No. 202011063762.8, titled “INTEGRATED ELECTRIC DRIVE SYSTEM AND ELECTRIC VEHICLE,” filed by BYD Co., Ltd. on September 30, 2020. AREA

[0002] The present disclosure relates to the technical field of electric vehicles, more particularly to an integrated electric drive system and an electric vehicle. BACKGROUND

[0003] An electric drive system is a core component of an electric vehicle. With the continuous development of new energy-powered vehicles, increasingly stringent requirements are placed on the design of the vehicle drive system. The electric drive system is composed of components such as a drive motor, a motor controller, a gearbox, an air compressor, a water pump, a vehicle controller, an on-board charger, and a DC-DC converter. In the relevant prior art, an integrated control housing of the electric drive system is generally mounted on a top surface of a stator housing of the drive motor, the gearbox is mounted on an output shaft end of the drive motor, and the air compressor is suspended from the gearbox via a bracket.However, such an integrated electric drive system has disadvantages such as a large overall weight, a low degree of integration, a large housing space, and high costs for molds and materials, etc. SUMMARY

[0004] The present disclosure provides an integrated electric drive system and an electric vehicle to solve the technical problems such as a low degree of integration and a large package space of the electric drive system in the prior art.

[0005] In view of the above problems, an integrated electric drive system provided in an example of the present disclosure includes a motor, a reduction gear, a controller, and a one-piece housing. A first housing space having a first opening and configured for mounting the controller is recessed into the one-piece housing. A second housing space configured for mounting the motor and a third housing space configured for mounting the reduction gear are arranged in a direction of the one-piece housing away from the first opening. The controller is connected to the motor. An output shaft of the motor is connected to the reduction gear.

[0006] An absolute value of a difference between a preset mounting width value and a width value of the first housing space is less than or equal to a first difference threshold in a direction parallel to the motor output shaft. The preset mounting width value is a sum of a width value of the second housing space and a width value of the third housing space.

[0007] An absolute value of a difference between a length value of the first housing space and a length value of the third housing space is less than or equal to a second difference threshold in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane.

[0008] In some examples of the present disclosure, an absolute value of a difference between one half of the length value of the first housing space and the length value of the second housing space is less than or equal to a third difference threshold in the direction perpendicular to the output shaft of the motor and parallel to the horizontal plane.

[0009] In some examples of the present disclosure, the first difference threshold is zero.

[0010] In some examples of the present disclosure, the second difference threshold is zero.

[0011] In some examples of the present disclosure, the third difference threshold is zero.

[0012] In some examples of the present disclosure, the integrated electric drive system further includes an air conditioning compressor and a bracket mounted on an end surface of the reduction gear remote from the second housing space. The air conditioning compressor is mounted on the bracket and connected to the controller.

[0013] In some examples of the present disclosure, the integrated electric drive system further includes a water pump mounted to the bracket and connected to the controller.

[0014] In some examples of the present disclosure, the bracket includes a vertical plate and a transverse plate connected to an upper end of the vertical plate. The vertical plate is mounted on an end surface of the reduction gear remote from the engine, the water pump is mounted above the transverse plate, and the air conditioning compressor is mounted on a side of the vertical plate remote from the reduction gear and located below the transverse plate.

[0015] In some examples of the present disclosure, the controller includes a capacitor module, an IGBT module, a three-phase copper bus, a DC bus, an on-board charger, and a DC-DC converter. The on-board charger and the DC-DC converter are both connected to a vehicle battery. The capacitor module, the IGBT module, the three-phase copper bus, the on-board charger, and the DC-DC converter are all mounted in the first housing space. The capacitor module is connected to the vehicle battery via the DC bus mounted on the one-piece housing. The three-phase copper bus is connected to a three-phase terminal of the motor.

[0016] The vehicle battery drives the motor to rotate via the DC bus, the capacitor module, the IGBT module and the three-phase copper bar, which are connected in series.

[0017] In some examples of the present disclosure, the on-board charger and the DC-DC converter include a heat dissipation module, an electrical control element drive module, and a heater drive module. The heater drive module is mounted to the heat dissipation module, and the electrical control element drive module is mounted to an end of the heater drive module remote from the heat dissipation module.

[0018] In some examples of the present disclosure, the first housing space includes a first interior space and a second interior space, both arranged side by side in a rectangular shape.

[0019] The capacitor module, the IGBT module, and the three-phase copper busbar are all mounted in the first compartment. The onboard charger and the DC-DC converter are mounted in the second compartment, and the DC bus is located on a side of the first compartment facing away from the second compartment.

[0020] In some examples of the present disclosure, the one-piece housing includes a first cooling water channel, a second cooling water channel, a water channel inlet, and a water channel outlet. The first cooling water channel is disposed at a position in the one-piece housing opposite the IGBT module, and the second cooling water channel is disposed at a position in the one-piece housing opposite the on-board charger and the DC-DC converter.

[0021] One end of the water channel inlet is connected to a preset water inlet device, the other end of the water channel inlet is connected to the first cooling water channel and the second cooling water channel, and the water channel outlet is connected to ends of the first cooling water channel and the second cooling water channel remote from the water channel inlet.

[0022] In some examples of the present disclosure, the motor includes an outer casing connected to the reduction gear and an inner casing inserted into the outer casing. A cooling space is formed between an inner wall of the outer casing and an outer wall of the inner casing. A water inlet and a water outlet, both communicating with the cooling space, are disposed on the outer casing. An end of the water channel outlet remote from the first cooling water channel communicates with the water inlet.

[0023] In some examples of the present disclosure, a plurality of ribbed flow deflectors are arranged on the outer wall of the inner housing in a circumferential direction of the output shaft of the motor.

[0024] In some examples of the present disclosure, the reduction gear includes a main shaft, an intermediate shaft, an output shaft, a drive gear, a driven gear, an intermediate drive gear, and an intermediate driven gear. The main shaft is connected to the output shaft of the motor. The drive gear is mounted on the main shaft, the intermediate drive gear and the intermediate driven gear are both mounted on the intermediate shaft, and the driven gear is mounted on the output shaft. The intermediate drive gear meshes with the drive gear, and the intermediate driven gear meshes with the driven gear.

[0025] An intermediate shaft axis is higher than the main shaft and output shaft axes. An included angle between a line connecting a center point of the main shaft to a center point of the output shaft and the horizontal plane is less than or equal to a preset angle on a plane perpendicular to the main shaft axis.

[0026] In some examples of the present disclosure, a battery mounting space configured for mounting a battery is arranged on an end surface of the one-piece housing facing away from the first opening.

[0027] In some examples of the present disclosure, the integrated electric drive system further includes a housing cover adaptively connected to the first opening.

[0028] In the present disclosure, the integrated electric drive system integrates the controller, the motor, and the reduction gear. The controller is mounted in the first housing space within the one-piece housing, and the motor and the reduction gear are mounted in the second housing space and the third housing space below the one-piece housing, respectively. Furthermore, an absolute value of a difference between a sum of the width value of the second housing space and the width value of the third housing space and the width value of the first housing space is less than or equal to the first difference threshold. The absolute value of the difference between the length value of the first housing space and the length value of the third housing space is less than or equal to the second difference threshold in the direction perpendicular to the output shaft of the motor and parallel to a horizontal plane.With the above arrangement, the mounting space of the integrated electric drive system is more balanced in all directions, and large hanging space is eliminated in all directions, improving the one-piece housing design and the noise, vibration, and harshness (NVH) of the vehicle. Furthermore, the integrated electric drive system has a high degree of integration, which reduces the mounting space of the integrated electric drive system on the vehicle, thereby making room for a larger motor. Furthermore, the integrated electric drive system with the high degree of integration eliminates the need for complex wiring harness connections between components.

[0029] An example of the present disclosure further provides an electric vehicle including the integrated electric drive system described above.

[0030] Additional aspects and advantages of the present disclosure will be set forth in part in the description which follows, and in part will be apparent from the description which follows, or may be learned by practice of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic diagram of an exploded structure of an integrated electric drive system according to an example of the present disclosure. Fig. 2 is a schematic diagram of an assembly structure of an integrated electric drive system according to an example of the present disclosure. Fig. 3 is a schematic diagram showing the arrangement of a first housing space, a second housing space, and a third housing space of an integrated electric drive system according to an example of the present disclosure. Fig. 4 is a schematic structural diagram of an integrated electric drive system according to an example of the present disclosure. Fig. 5 is a schematic structural diagram of a controller of an integrated electric drive system according to an example of the present disclosure. Fig. 6 is a schematic structural diagram of an on-board charger and a DC-DC converter of an integrated electric drive system according to an example of the present disclosure. Fig. 7 is a schematic diagram of a first cooling water channel and a second cooling water channel of an integrated electric drive system according to an example of the present disclosure. Fig. 8 is a schematic structural diagram of a reduction gear of an integrated electric drive system according to an example of the present disclosure. DETAILED DESCRIPTION

[0031] To clarify the technical problems, technical solutions, and advantageous effects to be solved in the present disclosure, the present disclosure will be described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific examples described herein are merely illustrative of the present disclosure and are not intended to limit the present disclosure.

[0032] It should be understood that the orientation or positional relationships indicated by terms such as "top," "bottom," "left," "right," "front," "rear," and "center" are based on the orientation or positional relationships illustrated in the accompanying drawings and are used only for convenience and brevity in describing the present disclosure. They do not indicate or imply that the device or element mentioned must have a particular orientation or be constructed and operated in a particular orientation. Therefore, these terms should not be construed as limiting the present disclosure.

[0033] In order to better illustrate a structure of the integrated electric drive system and its connection relationship, the term “top” in the present disclosure means an actual direction pointing to the top of the vehicle (ie, above the Fig. 2), the term “below” in the present disclosure means an actual direction pointing towards the bottom of the vehicle (i.e., below the Fig. 2), the term “left” in the present disclosure means the left side of the Fig. 2 and the term “right” in the present disclosure means the right side of the integrated electric drive system shown in Fig. 2 shown integrated electric drive system.

[0034] As in Fig. 1 to Fig. 4, an integrated electric drive system provided in an example of the present disclosure includes a motor 1, a reduction gear 2, a controller 3, and a one-piece housing 4. A first housing space 41 having a first opening and configured to mount the controller 3 is formed in the one-piece housing 4. A second housing space 42 configured to mount the motor 1 and a third housing space 43 configured to mount the reduction gear 2 are arranged in a direction of the one-piece housing 4 away from the first opening. The controller 3 is connected to the motor 1. An output shaft 23 of the motor 1 is connected to the reduction gear 2. It can be assumed that the first housing space 41 is located in the one-piece housing 4, and the second housing space 42 and the third housing space 43 are located on the left and right sides, respectively.right side below the one-piece housing 4. However, the controller 3 includes an engine controller, a vehicle battery controller, a vehicle battery charging / discharging device, and the like.

[0035] As in Fig. 3 and Fig. 4, an absolute value of a difference between a preset mounting width value and a width value of the first housing space 41 is less than or equal to a first difference threshold in a direction parallel to the output shaft 23 of the motor 1. The preset mounting width value is a sum of a width value of the second housing space 42 and a width value of the third housing space 43. In some examples of the present disclosure, the preset mounting width value and the width value of the first housing space 41 are substantially equal. That is, the width value of the first housing space 41 is equal to a sum of the width value of the second housing space 42 and the width value of the third housing space 43. In other words, the motor 1 and the reduction gear 2 fill a lower part of the one-piece housing 4 in the width direction of the one-piece housing 4 (i.e., in the direction parallel to the output shaft 23 of the motor 1).It can be assumed that the first difference threshold can be further adjusted according to an actual need, for example, a value range is 0-1 cm (e.g., 3 mm, 6 mm, 9 mm, and the like).

[0036] An absolute value of a difference between a length value of the first housing space 41 and a length value of the third housing space 43 is less than or equal to a second difference threshold in the direction perpendicular to the output shaft 23 of the motor 1 and parallel to a horizontal plane. In some examples of the present disclosure, the length value of the first housing space 41 and the length value of the third housing space 43 are substantially equal. That is, the length value of the first housing space 41 is equal to a length value of the third housing space 43. In other words, the reduction gear 2 fills a lower side of the one-piece housing 4 in a length direction of the one-piece housing 4. It can be assumed that the second difference threshold can be further adjusted according to an actual need; for example, a value range of the second difference threshold is 0-1 cm (e.g.,3 mm, 6 mm, 9 mm and the like).

[0037] In the present disclosure, the integrated electric drive system integrates the controller 3, the motor 1, and the reduction gear 2. The controller 3 is mounted in the first housing space 41 within the one-piece housing 4, and the motor 1 and the reduction gear 2 are mounted in the second housing space 42 and the third housing space 43, respectively, below the one-piece housing 4. Moreover, an absolute value of a difference between a sum of the width value of the second housing space 42 and the width value of the third housing space 43 and the width value of the first housing space 41 is less than or equal to the first difference threshold. The absolute value of the difference between the length value of the first housing space 41 and the length value of the third housing space 43 is less than or equal to the second difference threshold in the direction perpendicular to the output shaft 23 of the motor 1 and parallel to the horizontal plane.With the above arrangement, the mounting space of the integrated electric drive system is more balanced in all directions, and no large hanging space is left in all directions, which improves the modality of the one-piece housing 4 and the noise, vibration, and harshness (NVH) of the vehicle. Furthermore, the integrated electric drive system has a high degree of integration, which reduces the mounting space of the integrated electric drive system on the vehicle, thereby making room for the enlargement of the motor 1. Furthermore, the integrated electric drive system with the high degree of integration eliminates the need for complex wiring harness connections between components.

[0038] In an example, as in Fig. 2, an absolute value of a difference between one-half of the length value of the first housing space 41 and the length value of the second housing space 42 is less than or equal to a third difference threshold in a direction perpendicular to the output shaft 23 of the motor 1 and parallel to the horizontal plane. In some examples of the present disclosure, half of the length value of the first housing space 41 and the length value of the second housing space 42 are substantially equal. That is, an assembly length of the motor 1 is half of the length of the one-piece housing 4 in the length direction of the one-piece housing 4, and the length of the second housing space 42 is only half of the length of the first housing space 41, which is formed according to the shape of the motor 1.It can be assumed that the third difference threshold can be further adjusted according to actual needs. For example, a value range of the third difference threshold is 0-1 cm (e.g., 3 mm, 6 mm, 9 mm, and the like). By disposing the second housing space 42, the integrated electric drive system can have a higher degree of integration, further improving the NVH of the vehicle.

[0039] In an example, as in Fig. 1 and Fig. 2, the integrated electric drive system further includes an air conditioning compressor 8 and a bracket 5 mounted on an end surface of the reduction gear 2 remote from the second housing space 42. The air conditioning compressor 8 is mounted on the bracket 5 and connected to the controller 3. In some examples of the present disclosure, the bracket 5 and the housing of the reduction gear 2 are integrally formed. It can be considered that the bracket 5 and the air conditioning compressor 8 are arranged on a side surface of the one-piece housing 4. The air conditioning compressor 8 is integrated into the integrated electric drive system through the bracket 5, which further improves the degree of integration of the integrated electric drive system.

[0040] In an example, as in Fig. 1 and Fig. As shown in Figure 2, the integrated electric drive system further includes a water pump 6 mounted on the bracket 5 and connected to the controller 3. It can be assumed that the water pump 6 can provide a water source for a vehicle wiper. Furthermore, the design of the water pump 6 further improves the degree of integration of the integrated electric drive system.

[0041] In an example, as in Fig. 1 and Fig. 2, the bracket 5 includes a vertical plate and a transverse plate connected to an upper end of the vertical plate. The vertical plate is mounted on an end surface of the reduction gear 2 remote from the engine 1, and the water pump 6 is mounted above the transverse plate. The air conditioning compressor 8 is mounted on a side of the vertical plate remote from the reduction gear 2 and is located below the transverse plate. It can be considered that the water pump 6 is arranged above the bracket 5, which facilitates a reduction in the length of a connecting pipe between the water pump 6 and the vehicle wiper, and the air conditioning compressor 8 is mounted below the bracket 5, which can maintain a sufficiently large space for the connection between the air conditioning compressor 8 and other components of a vehicle air conditioning system.In addition, the water pump 6 and the air conditioning compressor 8 are integrated into the integrated electric drive system through the bracket 5, thereby further improving the degree of integration of the integrated electric drive system.

[0042] In an example, as in Fig. As shown in Figure 5, the controller 3 includes a capacitor module 31, an IGBT (Insulated Gate Bipolar Transistor) module 32, a three-phase copper bar 33, a DC bus 34, an on-board charger, and a DC-DC converter 35. The on-board charger and the DC-DC converter 35 are both connected to a vehicle battery. The capacitor module 31, the IGBT module 32, the three-phase copper bar 33, the on-board charger, and the DC-DC converter 35 are all mounted in the first housing space 41. The capacitor module 31 is connected to the vehicle battery via the DC bus 34 mounted on the one-piece housing 4. The three-phase copper bar 33 is connected to a three-phase terminal of the motor 1. The on-board charger and the DC-DC converter 35 can be considered to be a device that integrates the on-board charger and the DC-DC converter.The on-board charger is capable of fully charging the vehicle battery safely and automatically. The on-board charger can dynamically adjust the charging current and voltage and execute appropriate actions to complete the charging process. However, the DC-DC converter can convert the high voltage of the vehicle battery into the low voltage required by a storage battery in the vehicle. The design of the on-board charger and the DC-DC converter 35 further improves the degree of integration of the controller 33.

[0043] The vehicle battery drives motor 1 to rotate via the DC bus 34, the capacitor module 31, the IGBT module 32, and the three-phase copper bar 33, which are connected in series. It can be assumed that the vehicle battery drives motor 1 to rotate via the above-mentioned path, and motor 1 drives the vehicle wheels to rotate via the reduction gear 2, thereby achieving the technical effect of the vehicle battery driving the vehicle wheels to rotate.

[0044] In an example, as in Fig. 6, the on-board charger and DC-DC converter 35 include a heat dissipation module 351, an electric control element drive module 352, and a heater drive module 353. The heater drive module 353 is attached to the heat dissipation module 351, and the electric control element drive module 352 is attached to an end of the heater drive module 353 remote from the heat dissipation module 351. It can be considered that the heat dissipation module 351 is integrated with a heat dissipation element, such as a straight heat sink, and the electric control element drive module 352 is mainly integrated with an electric control element of the on-board charger and DC-DC converter 35 (e.g., the electric control element drive module 352 is integrated with electric control elements that generate little heat, such as a heat sink).a vehicle controller, an air conditioning compressor 8 controller, a water pump 6 controller, and a vehicle battery controller). The heater drive module 353 is mainly integrated with heating elements of the on-board charger and the DC-DC converter 35 (for example, the heater drive module 353 is integrated with heating elements that generate a lot of heat, such as the vehicle controller, the air conditioning compressor 8 controller, the water pump 6 controller, and the vehicle battery controller). That is, the on-board charger and the DC-DC converter 35 include three layers. A middle layer is the heater drive module 353, a lower layer is the electric control element drive module 352, and an upper layer is the heat dissipation module 351.Since the heat dissipation module 351 is in contact with the cooling water channel inside the one-piece housing 4, the layered structure of the on-board charger and the DC-DC converter 35 improves the heat dissipation efficiency of the on-board charger and the DC-DC converter 35.

[0045] In an example, as in Fig. As shown in Figure 5, the first housing space 41 includes a first interior space and a second interior space, both arranged side by side in a rectangular shape. It can be assumed that the first interior space and the second interior space are located on the left and right sides of the one-piece housing 4, respectively.

[0046] The capacitor module 31, the IGBT module 32, and the three-phase copper bus 33 are mounted in the first interior space. The onboard charger and the DC-DC converter 35 are mounted in the second interior space, and the DC bus 34 is located on a side of the first interior space facing away from the second interior space. In some examples of the present disclosure, the capacitor module 31, the IGBT module 32, and the three-phase copper bus 33 are arranged one after the other in the first interior space. It can be assumed that the capacitor module 31, the IGBT module 32, the three-phase copper bus 33, and the onboard charger and the DC-DC converter 35 are properly mounted in the first housing space 41, eliminating the complex wiring harness connection between the components of the controller 3, increasing the compactness and reliability of the integrated electric drive system and improving the modality of the controller 3.

[0047] In an example, as in Fig. As shown in Figure 7, the one-piece housing 4 includes a first cooling water channel 44, a second cooling water channel 45, a water channel inlet, and a water channel outlet 47. The first cooling water channel 44 is disposed in the one-piece housing 4 at a position opposite the IGBT module 32, and the second cooling water channel 45 is disposed in the one-piece housing 4 at a position opposite the on-board charger and the DC-DC converter 35. It can be assumed that the first cooling water channel 44 is mainly configured to absorb the heat dissipated from the IGBT module 32, and the second cooling water channel 45 is mainly configured to absorb the heat dissipated from the on-board charger and the DC-DC converter 35.Specifically, a plurality of protrusions are arranged at a lower part of the heat dissipation module 351 of the on-board charger and DC-DC converter 35, and the protrusions are arranged opposite the second cooling water channel 45. The protrusions can increase a contact area between the heat dissipation module 351 and the second cooling water channel 45, thereby improving the heat dissipation efficiency of the heat dissipation module 351.

[0048] One end of the water channel inlet is connected to a preset water inlet device, the other end of the water channel inlet is connected to the first cooling water channel 44 and the second cooling water channel 45, and the water channel outlet 47 is connected to ends of the first cooling water channel 44 and the second cooling water channel 45 remote from the water channel inlet. It can be assumed that the first cooling water channel 44 and the second cooling water channel 45 are connected in parallel between the water channel inlet 46 and the water channel outlet 47. In the present disclosure, the design of the first cooling water channel 44 and the second cooling water channel 45 improves the heat dissipation efficiency of the controller 3 and thus increases the service life of the integrated electric drive system.

[0049] In an example, as in Fig. 1 and Fig. As shown in Figure 2, the motor 1 includes an outer casing 11 connected to the reduction gear 2, and an inner casing 12 inserted into the outer casing 11. A cooling chamber is formed between an inner wall of the outer casing 11 and an outer wall of the inner casing 12. A water inlet and a water outlet 111, both communicating with the cooling chamber, are disposed on the outer casing 11. An end of the water channel outlet 47 remote from the first cooling water passage 44 communicates with the water inlet. It can be considered that the design of the cooling chamber can improve the heat dissipation efficiency of the motor 1, thereby extending the service life of the motor 1.

[0050] Specifically, the cooling fluids flow in two paths from the water channel inlet. The cooling fluid in one path absorbs the heat of the IGBT module 32 through the first cooling water channel 44, and the cooling fluid in the other path absorbs the heat dissipated by the on-board charger and the DC-DC converter 35 through the second cooling water channel 45. The cooling fluids in both paths are collected by the water channel outlet 47 and flow into the cooling chamber through the water inlet. The cooling fluid absorbs the heat dissipated by the engine 1 in the cooling chamber and flows out of the water outlet 111. In the present disclosure, the cooling fluid can cool the IGBT module 32, the on-board charger, and the DC-DC converter 35, as well as the engine 1, increasing the utilization rate of the cooling fluid.

[0051] In an example, as in Fig. 1 and Fig. As shown in Figure 2, a plurality of ribbed flow guide plates are arranged on the outer wall of the inner casing 12 in a circumferential direction of the output shaft 23 of the engine 1. It can be assumed that the ribbed flow guide plates can cause the cooling fluid in the cooling chamber to flow in the circumferential direction of the inner casing 12, thereby improving the cooling performance of the engine 1.

[0052] In an example, as in Fig. As shown in Figure 8, the reduction gear 2 includes a main shaft 21, an intermediate shaft 22, an output shaft 23, a drive gear 24, a driven gear 25, an intermediate drive gear 26, and an intermediate driven gear 27. The main shaft 21 is connected to the output shaft of the motor 1. The drive gear 24 is mounted on the main shaft 21, the intermediate drive gear 26 and the intermediate driven gear 27 are both mounted on the intermediate shaft 22, and the driven gear 25 is mounted on the output shaft 23. The intermediate drive gear 26 is in mesh with the drive gear 24. The intermediate driven gear 27 is in mesh with the driven gear 25. It can be assumed that the output shaft 23 of the engine 1 passes sequentially through the main shaft 21, the drive gear 24, the intermediate drive gear 26, the intermediate shaft 22, the intermediate driven gear 27, the driven gear 25 and the output shaft 23 and then drives the vehicle wheel to rotate.

[0053] An axis of the intermediate shaft 22 is higher than axes of the main shaft 21 and the output shaft 23. An included angle between a line connecting a center point of the main shaft 21 to a center point of the output shaft 23 and the horizontal plane is less than or equal to a preset angle on a plane perpendicular to the axis of the main shaft 21. The preset angle can be set according to design requirements. A value range for the preset angle is, for example, -10 degrees to 10 degrees. In some examples of the present disclosure, an included angle between a line connecting a center point of the main shaft 21 to a center point of the output shaft 23 and the horizontal plane is 0 degrees.It can be assumed that the intermediate shaft 22 is arranged above the main shaft 21 and the output shaft 23, and that the intermediate drive gear 26 and the intermediate driven gear 27 are both arranged above the drive gear 24 and the output gear 25. The design of the reduction gear 2 can lower the center of gravity of the integrated electric drive system and the center of gravity of the vehicle, thereby improving the driving stability of the vehicle and increasing the driving pleasure of the vehicle.

[0054] In an example, as in Fig. 1 and Fig. 2, a battery mounting space 48, which is designed for mounting a battery, is arranged on an end surface of the one-piece housing 4 facing away from the first opening. It can be assumed that the integrated electric drive system further comprises a battery mounted in the battery mounting space 48. In one example, as shown in Fig. 2, the battery mounting space 48 has a second opening, and a direction of the second opening is perpendicular to a direction of the first opening. It can be considered that the battery mounting space 48 is integrated below the one-piece housing 4 so that the battery can be mounted in the battery mounting space 48. Note that the battery is a small 12V battery. The small battery is generally used for a low-power subsystem of the vehicle, such as a subsystem for opening / closing vehicle doors, a subsystem for starting the vehicle, and a subsystem for vehicle lighting. By designing the battery, the degree of integration of the integrated electric drive system is further improved.

[0055] In an example, as in Fig. 1 and Fig.2, the integrated electric drive system further comprises a housing cover 7 matching the first opening. It can be assumed that the housing cover 7 is connected to the one-piece housing 4 to protect the controller 3 inside the one-piece housing 4.

[0056] The above descriptions are merely preferred examples of the present disclosure and are not intended to limit the present disclosure. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present disclosure is within the scope of the present disclosure. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] CN 202011063762.8

[0001]

Claims

[1] An integrated electric drive system comprising a motor, a reduction gear, a controller, and a one-piece housing, wherein a first housing space having a first opening and adapted for mounting the controller is recessed into the one-piece housing; a second housing space adapted for mounting the motor and a third housing space adapted for mounting the reduction gear are arranged in a direction of the one-piece housing away from the first opening; the controller is connected to the motor; an output shaft of the motor is connected to the reduction gear; the second housing space is located below the first opening and the third housing space is located below the first opening. [2] The integrated electric drive system according to claim 1, wherein in a projection in a horizontal plane, a projection of the first housing space and a projection of the second housing space at least partially overlap and / or in a projection in the horizontal plane, a projection of the first housing space and a projection of the third housing space at least partially overlap. [3] The integrated electric drive system according to any one of claims 1 to 2, wherein the reduction gear comprises a main shaft, an intermediate shaft, an output shaft, a drive gear, a driven gear, an intermediate drive gear, and an intermediate driven gear; the main shaft is connected to the output shaft of the motor; the drive gear is mounted on the main shaft; the intermediate drive gear and the intermediate driven gear are both mounted on the intermediate shaft; the driven gear is mounted on the output shaft of the reduction gear; the intermediate drive gear is engaged with the drive gear; the intermediate driven gear is engaged with the driven gear, and an axis of the intermediate shaft is higher than axes of the main shaft and the output shaft of the reduction gear. [4] The integrated electric drive system according to claim 3, wherein an included angle between a line connecting a center of the main shaft to a center of the output shaft of the reduction gear and the horizontal plane is less than or equal to a preset angle on a plane perpendicular to the axis of the main shaft, and a value range of the preset angle is about -10 degrees to 10 degrees. [5] The integrated electric drive system according to any one of claims 1 to 4, wherein a preset mounting width value and a width value of the first housing space in a direction parallel to the output shaft of the motor are substantially equal; the preset mounting width value is a sum of a width value of the second housing space and a width value of the third housing space. [6] The integrated electric drive system according to any one of claims 1 to 4, wherein a length value of the first housing space and a length value of the third housing space are substantially equal in a direction perpendicular to the output shaft of the motor and parallel to the horizontal plane. [7] The integrated electric drive system according to any one of claims 1 to 4, wherein a preset mounting width value and a width value of the first housing space in a direction parallel to the output shaft of the motor are substantially equal; the preset mounting width value is a sum of a width value of the second housing space and a width value of the third housing space, and a length value of the first housing space and a length value of the third housing space in a direction perpendicular to the output shaft of the motor and parallel to the horizontal plane are substantially equal. [8] The integrated electric drive system according to any one of claims 1 to 7, wherein an absolute value of a difference between a preset mounting width value and a width value of the first housing space is less than or equal to a first difference threshold in a direction parallel to the output shaft of the motor; the preset mounting width value is a sum of a width value of the second housing space and a width value of the third housing space; and an absolute value of a difference between a length value of the first housing space and a length value of the third housing space is less than or equal to a second difference threshold in a direction perpendicular to the output shaft of the motor and parallel to the horizontal plane. [9] The integrated electric drive system of claim 8, wherein a value of the first difference threshold is about 1 cm. [10] The integrated electric drive system of claim 8, wherein a value of the second difference threshold is about 1 cm. [11] The integrated electric drive system according to any one of claims 1 to 10, wherein a half of a length value of the first housing space and a length value of the second housing space are substantially equal in the direction perpendicular to the output shaft of the motor and parallel to the horizontal plane. [12] The integrated electric drive system according to any one of claims 1 to 11, wherein an absolute value of a difference between half of a length value of the first housing space and a length value of the second housing space is less than or equal to a third difference threshold in the direction perpendicular to the output shaft of the motor and parallel to the horizontal plane. [13] The integrated electric drive system of claim 12, wherein the third difference threshold is about 1 cm. [14] The integrated electric drive system according to any one of claims 1 to 13, wherein the controller comprises a capacitor module, an IGBT module, a three-phase copper bar, and a DC bus; the capacitor module, the IGBT module, and the three-phase copper bar are all mounted in the first housing space; the capacitor module is connected to a vehicle battery via the DC bus mounted on the one-piece housing; the three-phase copper bar is connected to a three-phase terminal of the motor, and the vehicle battery drives the motor to rotate via the DC bus, the capacitor module, the IGBT module, and the three-phase copper bar connected in series. [15] The integrated electric drive system according to any one of claims 1 to 14, wherein the one-piece housing comprises a first cooling water channel, a water channel inlet and a water channel outlet; one end of the water channel inlet is connected to a preset water inlet device; the other end of the water channel inlet is connected to the first cooling water channel and the water channel outlet is connected to an end of the first cooling water channel remote from the water channel inlet. [16] The integrated electric drive system of any one of claims 1 to 15, further comprising a housing cover adaptively connected to the first opening. [17] An electric vehicle comprising the integrated electric drive system according to any one of claims 1 to 16.

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